Method of wrapping products



Oct. 6, 1970 s rn- ETAL 3,531,907

METHOD OF WRAPPING PRODUCTS Original Filed Dec. 28, 1966 5 Sheets-Sheet1 Ih'l/ENTORS BARTON K 5/7/77/ R/ILPH M GEOFF SR JAMES B; ROD/14h 5RHENRY E ORZECHOWSK/ JOSEPH S. HARTLE SR Oct. 6, 1970 B. K. SMITH EPA!-METHOD OF WRAPPING PRODUCTS Original Filed Dec. 28, 1966 5 Sheets-Sheet3 11M 'ENTORS' BARTON K. S/V/U/ RALPH W. GEOFF JAMES B. ROD/IAN SR HEN/xOAZECl/OWS'K/ 0a. 6, 1970 B. K. SMITH ETAL 3, ,9 7

METHOD OF WRAPPING PRODUCTS Original Filed Dec. 28, 19663 5 Sheets-Sheet3 INVENTORS BARTON K. S/V/fi/ RALPH W. GEOFF JAMES B. ROD/MN 5/3 HENRY EORZECHOWS'K/ JOSEPH 5. HARHE SR.

Oct. 6, 1970 K, s rr ETAL 3,531,907

METHOD OF WRAPPING PRODUCTS 5 Sheets-Sheet 4 Original Filed Dec. 28,1966 Oct. 6, 1970 B. K. SMITH ETAL 3,531,907

METHOD OF WRAPPING PRODUCTS Original Filed Dec. 28. 1966 5 Sheets-Sheet5 i i 1 P93 1/98 P98 95 23 i 9; 1 1 l l Q VI 4 an. g M011 m, 25 00 Q m/444 w, M3

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9i 9% 1 i I mMikII /00 7611111 [NI/[HIGHS BARTON K SW/TH RALPH W. GEOFF5/? JAMES B. ROD/MN SA. HENRY F ORZECHOWSK/ JOSf/ H 8. 14/4/3 75 3/). .Ma. 99 O 47 0/? Y3 United States Patent O 3,531,907 lVIETl-IOD OFWRAPPING PRODUCTS Barton K. Smith, 801 Locust, Winnetka, Ill. 60093;Ralph W. Groff, Sr., 325 Plymouth Place, Cherry Hill, NJ. 08034; JamesB. Rodman, Sr., 450 Locust Ave Burlington, N.J., 08016; Henry F.Orzechowski, 201 E. Elm Ave., Lindeuwold, NJ. 08021; and Joseph S.Hartle, Sr., 508- N. Stanwick Road, Moorestown, NJ. 08057 Originalapplication Dec. 28, 1966, Ser. No. 605,321, now Patent No. 3,478,487,dated Nov. 18, 1969. Divided and this application Jan. 14, 1969, Ser.No. 810,887

Int. Cl. B65b 43/00 US. Cl. 53--29 2 Claims ABSTRACT OF THE DISCLOSUREAn apparatus and method for packaging articles of variable height. Thearticles are stacked and the height measured. A half-slotted containeris then cut to size and scored and slotted. The blank is partiallyerected and the articles placed into the container through an open side.The container is then closed.

CROSS-REFERENCE TO RELATED APPLICATION This is a division of applicationSer. No. 605,321, filed Dec. 28, 1966, now Pat. No. 3,478,487, issuedNov. 18, 1969.

This invention relates to a method of forming, filling and enclosingproducts within containers. More specifically, this invention relates toa method of wrapping products of fixed lengths, fixed widths and varyingheights within containers.

In the art of packaging products of fixed length and width and varyingheights, it is the practice to form blanks for each size product to bepackaged. The blanks are folded along the usual score lines and formedinto a tubular configuration by a manufacturers joint with a top andbottom thereof open. They are then knocked down for storage. When theyare to be used, they must be set up and telescoped over the product orthe product must be placed into the open-ended container. This prac ticehas proved to be unsatisfactory because a machine is required for eachstep in the assembly of the blanks that packages the product whichsubstantially increases the cost. Moreover, the manufacturer is requiredto maintain a large inventory of knocked down containers of varyingsizes together with aninventory of filler pads for insertion into thefilled containers to insure a tight package. Also, normal heightvariation in so-called standard size products will result in thecontainer selected being slightly too small or too large. Thus, a tightpackage of the product is not obtained.

The object of this invention is to provide a method of tightly packagingproducts having fixed width and length and varying heights.

Another object of this invention is to provide a method of sensing theheight of a product to be packaged and then wrapping the product withpackaging material that is the exact height of the product.

Another object of this invention is to provide a method of wrappingproducts wherein a half-slotted blank is cut to the exact dimension ofheight of the product in response to a sensing means that measures theexact height of the product to be packaged.

Another object of this invention is to provide a method of wrappingpackaging material around the product to be packaged wherein thepackaging material is cut to the exact dimensions of the product.

It has been discovered that products of a fixed length,

3,531,907 Patented Oct. 6, 1970 fixed width and varying height can betightly fitted into packaging material. This is accomplished by amachine which measures the height of the product which is to bepackaged, finishes a partially slotted and scored container blank,partially forms the container blank to fit and receive the product,finishes wrapping the container around the product, forms amanufacturers joint, closes and seals the closure flaps and dischargesthe package. As the product enters the machine, a sensing plate isbrought to bear on the top of the product to measure the height thereof.A half-slotted container blank is then fed from a hopper into a diecutter which slots the container blank, trims it and scores it accordingto the sensing plates measurement. The resulting regular slottedcontainer blank moves into a folding station where it is folded into agenerally U-shape with lower end wall closure flaps folded to and onelower sidewall closure flap folded to 45. There, the partially formedcontainer is positioned to accept and be wrapped around the product forwhich it is specifically sized. With wrapping completed, adhesive isapplied to form the manufacturers joint. Adhesive is applied to theflaps which are folded as the completed package moves from the assemblystation to the take-away conveyer.

These and other objects and advantages will become manifestly clear tothose skilled in the art when taken in conjunction with the detaileddrawings and description, wherein:

FIG. 1 is a perspective schematic illustration of the apparatus of thepresent invention.

FIG. 2 is a top view with parts shown in cross section of the containerillustrating the manner in which the container is folded around theproduct.

FIG. 3 is a view similar to FIG. 2 illustrating the manner in which theglue flap is formed into the manufacturers joint.

FIG. 4 is a perspective view of the partial erecting and rotating meanswith the blank in position to be folded.

FIG. 5 is a perspective view similar to FIG. 4 but illus trating thelower flaps of the blank being folded into position.

FIG. 6 is a perspective view similar to FIG. 4 but illustrating theblank being formed into another position.

FIG. 7 is a perspective view similar to FIG. 6 but illustrating thepartial erecting and rotating means rotated 90 with the blank ready toreceive the material to be packaged.

FIG. 8 is a perspective view of the container with the product thereinillustrating the manner in which the container is wrapped around theproduct.

FIG. 9 is a perspective view similar to FIG. 8 but illustrating themanner in which the bottom flaps are closed.

FIG. 10 is a bottom view of the package as it approaches the flapclosing means.

FIG. 11 is a bottom view of the package illustrating the manner in whichthe bottom flaps are closed.

FIG. 12 is a plan view of the half-slotted blank used with the presentinvention.

FIG. 13 is a plan view of a regular slotted container blank and theproducts to be packaged therein after the blank has been cut to theexact size of the height of the product to be packaged.

FIG. 14 is a view of a blank similar to FIG. 13 but illustrating a blankof a different height.

FIG. 15 is a view similar to FIG. 14 but illustrating a blank forpackaging a product of yet a still different height.

Referring to FIG. 12 of the drawings, a half-slotted blank 40 isillustrated that is usable with the present invention. The blank 40 isprovided with a plurality of vertical score lines 98 to provide theblank 40 with side walls 93 and end walls 94 and a glue flap 97. A lowerhorizontal score line 99 is provided in the conventional manner to formlower side wall closure Walls 95 and lower end wall closure flaps 96.Slots 100, coaxial with the vertical score lines 98 are provided in theusual manner to separate the flaps 95 and 96 in the usual manner.

In FIG. 13, a completed regular slotted blank is illustrated forreceiving the product 19. As illustrated, the height of the product 19is indicated at A. As hereinafter set forth, this height A is measuredby a sensing means and then the half-slotted container 40 is formed withan upper score line 102 which will provide a distance A between lowerhorizontal score line 99 and upper horizontal score line 102.Simultaneously with forming the upper score line 102, the upper sidewall closure flaps 103 and upper end wall closure flaps 104 are formedwith slots 101 therebetween. Also, a portion of the glue flap 97 isremoved to form a conventional container blank. In FIG. 14, thehalf-slotted container blank 40 is illustrated as being cut to a size toreceive a product 19 of a different height. As illustrated, the heightof the product 19' is indicated at B and the distance between lowerhorizontal score line 99 and upper horizontal score line 102 is thedistance B. Since the height of the product 19' is smaller than theheight of the product 19 in FIG. 13, additional material D is removedfrom the upper portion thereof. In FIG. 15, the half-slotted blank 40 isillustrated as being cut to a size C to receive a product 19" having aheight C. Since the height of the material 19" is smaller than theproduct 19', additinal material E is removed as waste. The regularslotted container blanks illustrated in FIG. 13, 14, and 15 areidentical with each other except for the height between the lowerhorizontal score line 99 and upper horizontal score line 102. The sizeof the half-slotted blank 40 illustrated in FIG. 12 will be selected forthe maximum size of product to be packaged. Thus, if there is anyvariation in size between packages of products 19, the machine forforming the half-slotted blank 40 into a regular slotted blank willautomatically compensate therefor as hereinafter set forth.

Referring now to FIG. 1, the wrapping machine 1 includes a feeding andcollating conveyor 2 for stacking the product 19 in an orderly manner.The product 19 is then passed to a height sensing mechanism 20 whichaccurately determines the height of the product 19. The sensed stack ofproduct is advanced by means of conveyor 23 to inserter mechanism 26,said inserter mechanism moves the product 19 into the container forwrapping the product 19. The wrapping machine 1 is also provided with ablank slotting and scoring means 31 which forms the half-slotted blank40 into a regular slotted container blank. Located adjacent the blankslotting and scoring means 31 is a partial erecting and rotating means41 which includes the container blank folding means 48. As the blank 40is held in the position as indicated in FIG. 1, the product 19 is loadedinto the partially folded blank and then the side wall 93 thereof isfolded around the product and a manufacturers joint is formed. Anejector mechanism 74 pushes the container which has been wrapped aroundthe product 19 past bottom flap folding means 83 and onto a ramp 89where the container is then removed to a top closing mechanism which maybe positioned in tandem relationship with the ramp 89.

In the illustration of the present invention, the product 19 beingpackaged is reams of paper that are being stacked five high with twostacks being packaged within one container. However, it is to beunderstood that other products can be packaged using the presentinvention. As illustrated in FIG. 1, the feeding conveyor 2 is providedwith a belt 3 extending around pulleys 4 and 5, one of which is driven.The feeding conveyor 2 is provided with guides 6 and 7 that are movableacross the belt 3 to guide the reams of paper 19 into the properposition. At the exit end of the feeding conveyor 2 are dual tippleconveyors 8 extending around pulleys 9 and 10. The tippleconveyors 8 aremovable up and down so as to stack the reams of paper one on top of theother to form a stack as illustrated in FIG. 1. Dual stacking conveyors11 receive the stacked reams of paper from the tipple conveyors 8 andmove the same to another conveyor 14. The stacking conveyors 11 extendaround pulleys 12 and 13 in the usual manner.

When sufficient reams of paper have been stacked onto the conveyor 14,they are moved from the stacking position to a position under the heightsensing means 20 by a motor means 16. Cylinder 17 having a piston rod18, a piston, not shown, and a plate constitute a squaring device toensure the proper advance of the piled stacks of product 19. The sensingmeans 20 consists of a rod 21 which is mechanically or otherwiseactuated to move in a vertical plane. Mounted on the lower end of therod 21 is a plate 22 which engages the top of the product 19 to bepackaged. When the sensing means 20 is actuated, the exact height of theproduct 19 is accurately measured. This distance is then relayed to theblank slotting and scoring means 31. Accordingly, the height of thecontainer for the particular package underneath the sensing means 20 isexactly determined.

The product 19 is then moved by means of conveyer 23, which is mountedaround the pulleys 24 and 25, from the sensing means 20 to the insertertray which is part of air motor 27 assembly. The inserting means 26includes a tray over fork arrangement, the tray receiving the product 19from the sensing means, said tray being withdrawn from the product 19 bymeans of air motor 27 having a cylinder 28, a piston rod 29 and apiston, not shown. When the tray is withdrawn, the product 19 is droppedvertically upon a support (not shown) which is part of plate 30. Thisplate and fork arrangement 30 is mounted on a chain which is actuated bya motor unit. Plate and fork arrangement 30 moves the product 19 to theleft as indicated by arrow in FIG. 1. Product 19 is inserted into thepartially folded container by means of plate and fork arrangement 30. Toensure product remaining in the partially folded container a verticallyoperated stripping plate, not shown, is raised beneath and between thefork of arrangement 30 thus retaining product 19' in container whileplate and fork arrangement 30 is retracted.

The blank slotting and scoring means 31 is provided with a frame 34which supports a table 32 and movable pivotally mounted stop member 33.Also, feed rolls 35 and 37 are provided to move the half-slotted blankinto position and to move the fully slotted blank from the machine. Therolls 35 and 37 are mounted on shafts 36 and 38 to rotate in oppositedirections to move the blank 40 from the blank slotting and cuttingmeans 31. As is conventional, the blank slotting and scoring means isprovided with a scoring means and a cutting means to form the upperflaps 103 and 104 and slots 101 along with upper horizontal score line102. The stop member 33 in the scoring and cutting mechanism 31 is movedwithin the blank slotting and scoring means 31 in response to the heightsensing means 20 to accurately position the blank 40 in mechanism 31 sothat it is die cut to the exact height of the product 19. After theblank 40 has been formed, the stop 33 pivots downwardly out of the ofthe blank 40 and the feeding wheels 35 and 37 are actuated to move theblank on the table 32 into the position as shown in FIG. 1 and FIG. 4onto the partial erecting and rotating means 41. As is conventional, abundle of blanks 39 is positioned to be fed from the lower portionthereof into the blank slotting and scoring means 31.

The machine 1 is provided with a partial erecting and rotating mechanism41 which is illustrated as being rectangular in form. The partialerecting and rotating means is mounted on hollow trunnions 42 and 43.with the ends closed by plate members 44 and 45. The hollow trunnionsrotate about a fixed shaft, not shown, which extends laterally acrossthe erecting and rotating means and is anchored at each end outside theoperating areas of trunnion 42 and 43. The ends 44 and 45 are connectedtogether by rails 47. Each of the rails 47 is provided with stop lips 46which are engageable with the blank to retard the advance of the blank40. Each side of the rectangular partial erecting and rotating mechanism41 is provided with a container folding means 48 which includes sideflap folding means 54, end flap folding means 49 and end wall foldingmeans 50. The side flap folding means 54 is mounted on pivots 55 on theframe structure to rotate the side flap folding means to which in itsrotation causes end flap folders 49 to fold about pivots 51 mounted onend wall folding means to fold the end flaps 96 to 90 with respect tothe end walls thereof. The end wall folding means 50 is mounted onpivots 52 to fold the end walls 94 to about 87 with respect to the sidewalls 93 (see FIG. 6).

To ensure that the blank 40 is properly maintained on the partialerecting and rotating mechanism 41, a blank holding means 56 is providedwhich includes a shoe 57 that engages one of the side walls 93 to holdthe same in proper position. The shoe 57 is mounted on support arms 58which in turn are supported by a support rod 59. As can be seen in FIG.4 and FIG. 5, the rod 59 will rotate the blank holding means toward andaway from the blank 40.

After the blank has been folded or partially erected as illustrated inFIG. 6, the blank holding means 56 is retracted to position as indicatedin FIG. 4. The partial erecting and rotating means 41 is then rotatedthrough 90 to place the container blank with an open side in position toreceive product 19 for packaging. To ensure this position of partialerecting and rotating means 41 a pin and stop arrangement is providedwith the stop mounted on the side plate 44 with the pin mechanismmounted from the fixed shaft supporting frame. This position isillustrated in FIG. 7. A side wall folding arm 60 is provided having arod member 61 vertically mounted thereon. The arm 60 is pivotallymounted on a pivot 62. As is more clearly seen in FIGS. 2, 3, 7 and 8,the rod 61 engages the side wall 93 containing the glue flap 97 to foldthe same along one of the vertical score lines 98 to completely enclosethe product 19. As is illustrated in FIG. 8, side wall folding arm 60 ispivotally mounted at 62 which is supported by a post 65. A linkage 64connects the arm 60 with an air motor 66 which in cludes a cylinder 67having a piston rod 68 extending out one end thereof with a yoke 69pivotally connected to the linkage 64. In this manner, the folding arm60 can be rotated to close the side wall thereof. When it is desired toadhere the glue flap to the end wall, a glue applicator 63 is actuatedto move adjacent the end wall that is adjacent the glue flap 97 andapplies a glue line thereon. A vertical pivotal dual rod 70 is providedwhich is adapted to be rotated about a linkage 71 which is pivotallyconnected at 72 to a support 73 to fold the glue flap 97 adjacent to theend wall and close the same. This is illustrated in FIGS. 3 and 7.

After the glue flap 97 has been adhered to the end wall, the containercontaining product 19 will be ejected therefrom by an ejector means 74which includes a chain 75 eXtending around sprocket 76 which is mountedon shaft 77. The chain is provided with an abutment 78 to move thecontainer from the position shown in FIG. 1 to the left thereof. Theejector mechanism 74 functions in a reversible manner so that theabutment 78 moves the partially packed or closed container toward theleft as illustrated in FIG. 1 and then reverses itself in response tothe rotation of shaft 77.

Adhesive applicators 79 and 80 are provided on each side of the lowerportion of the container so as to apply an adhesive on the interiorsurface of the lower side wall closure flaps 95. As illustrated in FIG.7, the adhesive applicators 79 and 80 are mounted on support plates 81and 82. At the time side panel 93 is folded, the support plate 81 withits adhesive applicators is raised to position for application ofadhesive on side flap 95. In the upward motion of the support plate 81 atoggle lever is provided to return side flap 95 to a vertical positionfrom its 45 position so that said side flap can receive adhesive. Afteradhesive application support plate 81 with its adhesive applicators isreturned to a lowered position to permit passage of product filledcontainer by means of ejector means 74. Accordingly, as the container ismoved past the glue applicators by the abutment 78 in response to therotation of shaft 77, adhesive is applied to the flaps which aresubsequently closed.

As illustrated in FIGS. 1, 9, 10, and 11, the bottom side wall closingflaps 95 are folded adjacent to the bottom end wall closing flaps 96 byspring loaded flap closure means 83. The flap closing means 83 aremounted on each side of the path of travel of the container containingthe product so as to close each lower side wall closing flap. Each ofthe bottom side wallflap closing means 83 are pro vided with rollers 84which are mounted on an L-shaped arm 85 which is in turn pivotallymounted on the frame by a pivot pin 86. Accordingly, as the packedcontainer advances toward the rolls 84, the rolls pivot around the pivotpin 86 and the lateral portion 85 moves underneath the container to foldthe flaps 95 into position as illustrated in FIG. 11. The outer extremeend portions of the members 85 opposite the end mounting the rolls 84are provided with curved portions 87 to ensure that no inadvertentscoring or detainment of the flaps 95 occurs. This curved portion 87merely ensures that the container will not hang up in this position.

As the bottom closed container moves past the bottom side wall closingflaps 83, it is received on a receiving ramp 89 provided with arms 90and 91. The end portion of the arms 90 and 91 are provided with curvedportions 90' and 91 to ensure proper sliding movement of the loadedcontainer onto the ramp 89.

When the container reaches the receiving ramp 89, the bottom of thecontainer is completely closed with the top thereof remaining open. Thecontainer may then be passed through a conventional top closing machinewhich can be mounted in line with the ramp 89 to auto matically closethe top portion thereof.

In operation, it will be assumed that reams of paper are being packagedwithin the container blanks 40 and that there will be ten reams perpackage with the ten reams being divided into two separate stacks witheach stack being five reams high. It will further be assumed that thefeeding conveyer 2 has positioned a stack of ten reams of paper adjacentthe motor means 16 so as to move the same into the machine. It willfurther be assumed that a stack 39 of half-slotted blanks 40 arepositioned to be fed into the blank slotting and scoring means 31.

Accordingly, the motor 16 is actuated to move the product 19 to bepackaged on the conveyer 14 to a position directly underneath the heightsensing mechanism 20. Simultaneously with moving the product 19 underthe sensing means 20, a half-slotted blank 40 is stripped fromunderneath the stack 39 and moved to a position engageable with stop 33.Power means are now actuated to move the plate 22 on sensing means 20down on top of the product 19 to exert a slight pressure thereon.Accordingly, the height sensing means 20 measures the distance betweenthe upper and lower end of the product 19. This distance is transmittedby mechanical linkage or other means to the blank slotting and scoringmeans 31 which moves the stop member 33 that positions the blank 40properly therein to provide an upper score line, as indicated at 102 inFIG. 13, to provide a distance between the score lines 99 and 102 theexact height of the product 19 to be packaged. The power means thatactuated the sensing means 20 is then reversed to move the plate 22upwardly and away from the product 19. Simultaneously therewith, thestop 33 is pivoted downwardly and the feed wheels 37 and 35 feed the nowregular slotted blank toward the partial erecting and rotating means 41until the blank engages the stop lips 46.

With the blank 40 positioned on the partial erecting and rotating means41 as illustrated in FIG. 4, the blank holding means 56 is pivoted downto engage one side wall thereof with the end walls adjacent the outeredges thereof. This position is shown in FIG. 5. Thereafter, the sideflap folding means 54 is actuated and folded to a 45 angle which in turnactuates the end flap folding means 49 to fold the lower end flaps 96 to90 with respect to the end walls 94. Thereafter, the end walls 94 arefolded along score lines 98 so as to be positioned about 87 with respectto the side walls by the end wall folding means 50. Thus the side wall93 provided with the glue flap 97 is in the same plane as the end wall94. With the blank held in this position, power means is actuated torotate the means 41 to about 87 to position the partially erected blankin a position to receive the product 19 from the side thereof.

With the blank 40 partially erected, the product 19 is placed therein byactuating the loading mechanism 26 to slide the product 19 into thecontainer. Then the motor means 66 is actuated to move the side wallfolding arm 60 from a position as seen in FIG. 2 to a position adjacentthe side wall thereof to fold the side wall 93 along score line 98 tocompletely enclose the product 19 within the container. Thereafter, theglue applicator 63 is actuated to move toward the container whichapplies the proper amount of adhesive thereto. Thereafter, the

dual glue flap closure rods 70 are actuated to fold the glue flapadjacent the end wall as illustrated in FIG. 3 to close the containeraround the product 19. It is to be understood that the loading means 26moves toward and away from the open container so that it is out of theposition to interfere with the function of the closure rods 70 and 61.Thereafter, the rods 61 and 70 are positioned to return to theiroriginal position and the ejector means 74 is actuated so that theabutment means 78 moves the packaged container out of the machine.

As the package is being moved from the position as shown in FIG. 8, theglue applicators 79 and 80 apply a glue line on the lower side wallclosure flaps 95. The package then engages the lower side wall foldingmeans 83 as illustrated in FIGS. 10 and 11 to fold the lower side wallclosure flaps adjacent the lower end wall closure flaps and adheres thesame to close the lower end. The package is then moved onto the ramp 89for further processing to close the upper end thereof.

While specific details of a preferred embodiment have been set forthabove, it will be apparent that many changes and modifications may bemade therein without departing from the spirit of the invention. It willtherefore be understood that what has been described herein is intendedto be illustrative only and is not intended to limit the scope of theinvention.

What is claimed is:

1. A method of packing products within a container, comprising the stepsof: sensing the height of the product to be packaged; forming a regularslotted container blank in response to the height of the product to bepackaged to conform to the exact height dimension thereof; partiallyerecting said container blank so as to provide an opening on one sidethereof; loading the product within the container blank from the sidethereof; fully enclosing the product within the container blank; closingthe lower end thereof.

2. The method of claim 1 together with the additional step of rotatingthe container blank 90 prior to loading the product into the blank fromthe side thereof.

References Cited UNITED STATES PATENTS 7/1962 Eichorn et al. 53-66 X6/1967 Kingsbury et al. 53-183 X US. Cl. X.R. 5366

